Y4 Cross-Section Polyester Filament Air Filter Bonding
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Solution Overview
Problem
Existing air filter materials composed of laminated melt blown and spun bond nonwoven fabrics face challenges in maintaining air permeability due to the use of adhesives that fill openings in the spun bond fabric, reducing its efficiency.
Innovation Solution
The integration of ultrafine fiber nonwoven fabric with polyester nonwoven fabric using a specific hot melt adhesive agent, such as a powder or spider web type, with polyester continuous filaments having a unique 'Y4' cross-sectional shape, where the low melting point polyester component acts as an adhesive to enhance mechanical properties and prevent air permeability reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive agent is used to bond and integrate melt blown nonwoven fabric with spun bond nonwoven fabric, then the bonding strength is improved, but the air permeability is reduced due to adhesive flowing out and filling the openings
Solution Approach 1:
A low melting point polyester component is introduced as an intermediary substance within the sheath-core conjugate filament structure. The low melting point polyester (melting point 100-150°C) acts as a controlled adhesive that melts during heat embossing to bond the fabrics, while the high melting point polyester core (melting point 260-300°C) prevents excessive adhesive flow that would fill the openings and reduce air permeability.
Solution Approach 2:
The invention changes the melting point parameter of the adhesive component by using a low melting point polyester (100-150°C) significantly lower than the fiber melting points. This parameter change allows the adhesive to melt and flow at bonding temperatures without degrading the fiber structure or excessively filling the openings, thus maintaining air permeability while achieving adequate bonding strength.
2Strength
If heat compression is used to laminate and integrate the nonwoven fabrics, then the integration strength is improved, but the openings in spun bond nonwoven fabric are filled with molten adhesive, reducing air permeability
Solution Approach 1:
The sheath-core conjugate filament structure creates local quality differentiation within the fiber itself. The sheath component (low melting point polyester) provides localized adhesive function at the bonding interfaces, while the core component (high melting point polyester) maintains structural integrity and limits adhesive flow. This local quality approach ensures bonding occurs only where needed without excessive adhesive migration into the openings.
Solution Approach 2:
The invention uses a composite fiber structure combining two different polyester materials with distinct melting points. The sheath-core conjugate filament creates a composite material where the low melting point polyester provides bonding functionality while the high melting point polyester provides structural support, achieving both integration strength and air permeability retention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively maintains high air permeability and mechanical strength by using a hot melt adhesive with a melting point lower than the fibers, ensuring the adhesive does not fill openings and deplete air permeability, while providing a robust bonding between the ultrafine fiber and polyester nonwoven fabrics.
Implementation Method 1
the polyester continuous filaments are heat bonded with each other
Data Source
AI summary
An air filter material has spun bond nonwoven fabric and melt blown nonwoven fabric. The spun bond nonwoven fabric includes conjugate polyester continuous filaments having a “Y4”-like cross sectional shape. The Y-4 shape of the continuous filament is composed of plural nearly V-shape portions formed from low melting point polyester, joined by a nearly + shape portion formed from high melting point polyester. The continuous filaments are heat-bonded with each other by the low melting point polyester. The spun bond nonwoven fabric is bonded with the melt blown nonwoven fabric with a powder type or spider web type hot melt adhesive agent.